Chemical process for generating energy

ABSTRACT

A process for generating energy comprises process comprises exothermically reacting Mg with SiO 2  to yield at least Mg 2 Si and Si; b)reacting the Mg 2 Si to yield at least lower silanes, and at least one magnesium product; c) generating at least higher silanes from at least a portion of the lower silanes; d) combusting the higher silanes and the Si to yield at least one silicon product.

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims priority from U.S. provisional application61/041,036, filed on Mar. 31, 2008, which is incorporated herein byreference in its entirety.

FIELD

The specification relates to chemical processes, and more particularly,chemical processes which generate energy using inorganic sources.

INTRODUCTION

The following is not an admission that anything discussed below is priorart or part of the common general knowledge of persons skilled in theart.

United States Patent application Publication No. 2004/0063052 disclosesan energy concept that relates to an artificial silicon-nitrogen cycleand that constitutes the complement to the natural carbon-oxygen cycle.Pure silicon is produced from sand using solar energy. By repeatedMuller-Rochow synthesis with silylchlorides the silicon is converted tohigher silanes. The silylchlorides used are either silicons derived fromchemical wastes or are economically produced from monosilanes ordisilanes. They are mixed with silicon powder and combusted with air toproduce H₂O and silicon nitride Si₃H₄, thereby generating power. Thesilicon nitride is converted to ammonia NH₃ under alkaline conditions,thereby producing silicates. Part of the NH₃ is converted to follow-onproducts, the major portion however is combusted with air to produce H₂Oand N₂, thereby generating power. The N₂ cycle is thereby closed.

U.S. Pat. No. 5,996,332 discloses a method of driving a shaft byreaction of silanes with air in a double combustion chamber and anassociated drive mechanism. The hydrogen of the silanes reacts in thefirst combustion chamber with an insufficient level of oxygen of the airsupplied, thereby producing high temperatures. At these hightemperatures, the nitrogen from the air supplied reacts with the siliconof the silane to form silicon nitride. The resultant combustion gasesand dust and the non-combusted hydrogen are mixed in the secondcombustion chamber with a large quantity of cold compressed air. Thehydrogen undergoes late burning, and mixture subsequently enters aturbine chamber to actuate turbine blades connected to a shaft. Themethod is particularly environmentally-friendly since no toxic orpolluting waste gases are produced.

U.S. Pat. No. 6,736,069 discloses method for generating energy by usingexothermic reaction of a metal. The method consists of the followingsteps: reacting an oxidant containing mostly water with combustionsubstances mainly containing light metals to generate hydrogen; reactinggenerated hydrogen with nitric acid, sulfuric acid, chlorine peroxide,metal nitrate, metal perchlorate, metal sulfate, and hydrogen peroxideto generate water and heat; and continuously repeating the above twosteps with the use of water to gradually increase explosive power. Amethod for utilizing generated energy is also disclosed. The method cangenerate increased amounts of energy by repeatedly reacting oxidantssuch as water, liquid acid, and metal salt with combustion substancescontaining mostly light metals. According to the inventor, this methodhas economic advantages in that inexpensive substances such as lightmetal and oil are used as combustion substances.

U.S. Pat. No. 5,178,844 discloses a method and for producing a productcomprising a nitride compound, such as for example silicon nitride. Areactor is provided which has a chamber defined therein which is dividedinto a combustion zone and a reaction zone. A combustible mixture isinjected into the combustion zone in a direction generally toward thereaction zone, and is accordingly combusted in the combustion zone. Atleast one reactant is injected at the boundary between the zones intothe reactor chamber in a direction generally parallel to thelongitudinal axis of the chamber so as to react to from raw productcomprising the nitride compound. A raw product powder as produced by thereactor comprises silicon nitride as the nitride compound and furthercomprises elemental silicon.

SUMMARY

The following summary is provided to introduce the reader to the moredetailed discussion to follow. The summary is not intended to limit ordefine the claims.

Processes for generating energy are described herein. The processes arechemical processes for generating energy, and comprise a series ofchemical reactions, at least some of which are exothermic. The energygenerated by the exothermic reactions may be captured by any methodknown in the art, for example by the use of Stirling engines. Thecaptured energy may be, for example, sold to consumers. In addition, theprocess may comprise certain steps which are endothermic. The capturedenergy may be input into these endothermic steps. Accordingly, in someexamples, the process may not require any energy from outside of theprocess. Preferably, the processes are cyclic processes, in which atleast some of the products of the process are processed and recycledback to the start of the process.

According to one broad aspect, a process for generating energy isprovided. The process comprises a) exothermically reacting Mg with SiO₂to yield at least Mg₂Si and Si; b)reacting the Mg₂Si to yield at leastlower silanes, and at least one magnesium product; c) generating atleast higher silanes from at least a portion of the lower silanes; andd) combusting the higher silanes and the Si to yield at least onesilicon product.

Preferably, the process further comprises processing at least a portionof the magnesium product to yield Mg, and recycling at least a portionof the Mg back to step (a).

According to another broad aspect, another process for generating energyis provided. The process comprises a) exothermically reacting Mg withSiO₂ to yield at least Mg₂Si and Si; b)reacting the Mg₂Si with H₂ toyield at least lower silanes, and Mg; c) generating at least highersilanes from the lower silanes; and d) combusting the higher silanes andthe Si to yield at least one silicon product.

Preferably, the process further comprises recycling at least a portionthe Mg yielded in step (b) back to step (a).

According to another broad aspect, another process for generating energyis provided. The process comprises (a) exothermically reacting Mg withSiO₂ to yield at least Mg₂Si and Si; (b) reacting the Mg₂Si to yield atleast lower silanes, and at least one magnesium product; and (c)combusting at least a portion of the lower silanes.

DRAWINGS

FIG. 1 is a flow diagram of an example of a process in accordance withthe present invention;

FIG. 2 is a flow diagram of another example of a process in accordancewith the present invention;

FIG. 3 is a flow diagram of yet another example of a process inaccordance with the present invention; and

FIG. 4 is a flow diagram of yet another example of a process inaccordance with the present invention.

DESCRIPTION OF VARIOUS EXAMPLES

Various processes will be described below to provide an example of eachclaimed invention. No example described below limits any claimedinvention and any claimed invention may cover processes that are notdescribed below. The claimed inventions are not limited to processeshaving all of the features of any one process described below or tofeatures common to multiple or all of the processes described below. Itis possible that a process described below is not an example of anyclaimed invention. The applicants, inventors or owners reserve allrights that they may have in any invention disclosed in a processdescribed below that is not claimed in this document, for example theright to claim such an invention in a continuing application and do notintend to abandon, disclaim or dedicate to the public any such inventionby its disclosure in this document.

Referring to the flow chart of FIG. 1, a first example of a process 100is shown. Process 100 is a process for generating energy, and comprisesa series of chemical reactions, at least some of which are exothermic.The energy generated by the exothermic reactions may be captured by anymethod known in the art, for example by the use of Stirling engines. Thecaptured energy may be, for example, sold to consumers. In addition, theprocess may comprise some steps which are endothermic. At least aportion of the captured energy may be input into these endothermicsteps. Furthermore, process 100 is preferably a cyclic process, in whichat least some of the products of the process are processed and recycledback to the start of the process. The products of the various reactionsin the process may be separated from each other using any suitablemethod, such as centrifugation or filtration.

Step 101

Process 100 starts at step 101. The starting materials for step 101 areMg (line 102), and SiO₂ (line 104). At step 101, Mg and SiO₂ are reactedexothermically to yield at least Mg₂Si and Si. In the example shown, thereaction of Mg and SiO₂ further yields MgO. More particularly, the mainreactions at step 101 may occur according to the following formulas:

4Mg+SiO₂→2MgO+Mg₂Si   (1)

2Mg+SiO₂→2MgO+Si   (2)

Reactions (1) and (2) may occur simultaneously. In the example shown, atstep 101, Mg and SiO₂ react in the presence of a catalyst (line 106).The balance between reactions (1) and (2) may depend on the type andamount of catalyst present. In some examples, the catalyst may includecopper oxide or iodine.

Both reactions (1) and (2) are exothermic. The energy generated byreaction 1 may be approximately 295.8 kJ/mol Mg₂Si. The energy generatedby reaction 2 may be approximately 375 kJ/mol Si.

Additionally, the following reaction may occur at step 101:

Mg+Si→Mg₂Si   (3)

Reaction (3) is exothermic, and may yield approximately 79.8 kJ/mol Mg.

Additionally, some Mg may combine with some SiO₂ to form other magnesiumsilicides such as MgSi, and Mg₃Si₂.

In some examples, step 101 is carried out in the presence of air, whichcontains O₂ and N₂. In such examples, at least some of the Mg may reactwith the O₂ to yield MgO, and at least some of the Mg may react with theN₂ to yield Mg₃N₂. These reactions may occur according to the followingformulas:

2Mg+O₂→2MgO   (4)

3Mg+N₂→Mg₃N₂   (5)

Both reactions (4) and (5) are exothermic. The energy generated byreaction (4) may be approximately 601.5 kJ/Mol MgO. The energy generatedby reaction (5) may be approximately 461.3 kJ/Mol Mg₃N₂.

Preferably, the Mg is provided to step 101 in the form of a powdercomprising ultradispersed particles. For example, the particles may havean average diameter of less than 100 microns, and more specifically,between 70 microns and 1 micron. Alternately, the particles may benanoparticles, having a diameter of less than 1 micron. The magnesiummay contain small amounts of magnesium oxide, which may be present dueto naturally occurring oxidation. Other contaminants may be present aswell, such as Mg₃N₂. Preferably, the total contaminants do not exceed0.01 wt % of the total weight of the Mg.

In some examples, the SiO₂ is provided in the form of granules, such asin the form of sand.

Preferably, the Mg is collected on a layer of SiO₂ granules, and the Mgand SiO₂ are provided together to step 101. Such examples may beadvantageous because the risk of the Mg exploding may be reduced orminimized. In alternate examples, the Mg and the SiO₂ may be provided asa homogeneous mixture. In other alternate examples, the Mg and the SiO₂may be provided separately to step 101, and may be mixed during step101.

As will be described further hereinbelow, preferably at least some ofthe Mg provided to step 101 may be provided from steps furtherdownstream in the process. For example, at least some of the Mg used instep 101 may be produced in steps 121 or 123, and recycled back to step101. Preferably, between more than 90% of the Mg provided to step 101 isprovided from downstream steps. However, in alternate examples, lessthan 90% of the Mg provided to step 101 is provided from downstreamsteps. Further, at least some of the SiO₂ may be recycled to step 101from steps further downstream in the process.

Step 101 may be carried out in a vessel or container. In some examples,the vessel or container is capable of withstanding elevated reactiontemperatures, is inert to the reactants and products of step 101, and iscapable of conducting heat. More particularly, the vessel may be madefrom a metal, a metal oxide, or a metal alloy (e.g. aluminum, copper,ceramic, or a combination thereof). Such vessels are described in U.S.Pat. No. 5,178,844 (Carter et al.), and U.S. Pat. No. 6,436,356 (Koput);and U.S. Patent Application Publication 2003/0101850 (Vadchenko et al.).

The packing density of the vessel may vary. In some examples, 60% to 80%of the volume of the vessel may be filled by reactants, with theremaining portion filled with air. In alternate examples, step 101 maybe carried out in a vacuum or in a nitrogen atmosphere.

Preferably, the Mg and the SiO₂ are provided to the vessel in a 3:1 moleratio.

The reaction of Mg and SiO₂ may be carried out according to knownmethods for self-propagating high temperature synthesis. For example,the reaction may be initiated by providing a short term heat impulse(e.g., an electric spiral, laser, spark, etc.), such that a combustionwave is generated and spreads across the starting materials. Thereaction can last from less than one second up to several minutesdepending on the purity of the reactants. In some particular examples,the speed of the combustion wave is in the range of 0.1 to 20 cm/s. Thetemperature of combustion may be between 2300 to 3800 K. The energyneeded to generate a spark or otherwise initiate a combustion may bebetween 10 and 200 cal/cm²/sec.

The energy generated by the above reactions may be captured according tomethods known in the art, for example using Stirling engines.

In one particular example, step 101 may be carried out starting with 6mol of Mg and 2 Mol of SiO₂, which produces 1 mole of Mg₂Si powder, 1mol of Si, and 4 mol of MgO. Up to 0.24% of the Mg may react with oxygenand nitrogen in the air.

The resulting MgO may be in the form of a powder. The resulting Mg₂Simay be in the form of a powder. The resulting Si may be in the form ofan amorphous powder. The products may be separated and purified by knownmethods, such as centrifugation.

At least a portion of the Mg₂Si yielded in step 101 is forwarded to step103 (via line 108). The Si yielded in step 101 is forwarded to step 107(via line 112). Optionally some of the Si yielded in step 101 may beremoved from the process (via line 178) and may be used to generatesolar power. That is, some of the Si may be converted to solar-grade Si,which may be incorporated into solar panels. The energy generated by thesolar panels may be used to power steps of process 100 requiring energy,such as steps 115 and 119.

The MgO yielded in step 101 is optionally forwarded to step 123 (vialine 110), and the Mg₃N₂ yielded in step 101 is optionally forwarded tostep 117 (via line 152).

Step 103

At step 103, the Mg₂Si produced in step 101 is reacted to yield at leastlower silanes, and at least one magnesium product. As used herein, theterm lower silanes includes silanes having less than three siliconatoms, including SiH₄ and Si₂H₆. In the example shown, the magnesiumproduct includes MgCl₂ and Mg(OH)₂. More specifically, in the exampleshown, the Mg₂Si is exothermically reacted with aqueous HCl to yieldMgCl₂, Mg(OH)₂, SiH₄, Si₂H₆, and H₂. The reactions at step 103 may occuraccording to the following formulas:

Mg₂Si+4HCl→2MgCl₂+SiH₄   (6)

Mg₂Si+4H₂O→2Mg(OH)₂+SiH₄   (7)

The HCl is preferably a solution of between 0.1 to 5%. In alternateembodiments, another type of acid may be used.

Reaction (6) may be initiated by combining the reactants at roomtemperature. As reaction (6) occurs, the mixture becomes further heated,and as the mixture is further heated, reaction (7) occurs simultaneouslywith reaction (6).

Both reaction (6) and reaction (7) are exothermic. Reaction (6) mayyield approximately 508.4 kJ/mol SiH₄, and reaction (7) may yieldapproximately 593.8 kJ/mol SiH₄.

During step 103, trace amounts of H₂ may be formed (line 181). The H₂may be optionally be forwarded to other steps in the process requiringH₂, such as step 121, discarded, or used for another suitable purpose.

Additionally, the higher magnesium silicides formed in step 101 may beforwarded to step 103 together with the Mg₂Si. At step 103, Si₂H₆ may beformed by the reaction of the higher magnesium silicides with the HCl.This may occur according to the following formula:

Mg₃Si₂+6HCl→3MgCl₂+Si₂H₆   (8)

The lower silanes generated at step 103 are gaseous, and may beseparated from the remaining products by any suitable method, such asabsorption or rectification.

At least a portion of the separated lower silanes are forwarded to step105 (via line 114). For example, between 70% and 90% of the lowersilanes are forwarded to step 105. Optionally, a portion of the lowersilanes, for example 10% to 30% of the lower silanes, may be removedfrom the process (via line 180). The removed lower silanes may, forexample, be combusted in order to generate energy required to power theendothermic steps of the process 10, or reacted to obtain Si and H₂.

Preferably, at least a portion of the magnesium products generated atstep 103 are further processed to yield Mg, and are recycled back tostep 101. For example, as will be described further hereinbelow, in theexemplified process, the Mg(OH)₂ is forwarded to step 109 for furtherprocessing (via line 116), and the MgCl₂ is forwarded to step 115 forfurther processing (via line 118).

Step 105

At step 105, higher silanes are generated from at least a portion of thelower silanes formed in step 103. For example, approximately 70% to 90%of the lower silanes yielded in step 103 may be forwarded to step 105(via line 114). As used herein, the term higher silanes refers tosilanes having more than 3 silicon atoms and of the formulaSi_(x)H2_(x+2). For example, the higher silanes may include from 3 to 9or more silicon atoms (e.g. Si₃H₈ to Si₉H₂₀).

In some examples, the higher silanes may be generated according to knownmethods, such as those described in U.S. Pat. No. 6,027,705 (Kitsuno);Japanese unexamined patent publications (Kokai) 3-183613, 60-141613,62-132720, 62-132721 and 3-183614; and German Patent No. 2139155.

In one particular example, step 105 comprises separating the gaseouslower silanes into monosilane SiH₄ and disilane Si₂H₆, for example bycooling the gaseous mixture below the condensation temperature of thedisilane (i.e. below −14.8 degrees Celsius, optionally to about −20degrees Celsius). Then, using a parallel-plate RF (13.56 MHz) dischargeapparatus, such as that described in U.S. Pat. No. 5,562,690 (Cheung etal.), the gaseous monosilane is decomposed at 2.16 eV to yield SiH₂ andhydrogen, in accordance with the following formula:

e⁻+SiH₄→SiH₂+H₂+e⁻  (9)

In some examples, the energy generated in steps 101 and 103 may be usedto power the discharge apparatus. Alternately, some of the H₂ may beremoved and allowed to ignite to generate energy to power the dischargeapparatus. Alternately, some of the silanes may be removed and allowedto ignite to power the discharge apparatus.

The isolated Si₂H₆ is then heated back to a gaseous state (e.g. to atemperature of between 300° C. and 400° C.), and the SiH₂ is reactedwith the Si₂H₆ to yield higher silanes according to the followingformulas:

SiH₂+Si₂H₆→Si₃H₈   (10)

SiH₂+Si_(n)H_(2n+2)→Si_((n+1))H_([2(n+1)+2])  (11)

Reactions 10 and 11 are exothermic, and may generate approximately 233.6kJ/mol. Reactions 10 and 11 may be carried out according to any suitablemethod, such as that described in “Polysilane Production in RF SiH₄ andH₂—SiH₄ Plasmas”, by P. Horvath, K. Rozsa, and A. Gallagher, publishedin JILA, Univ. of Colorado and National Institute of Standards andTechnology, June 2003.

The higher silanes generated in step 105 are forwarded to step 107 (vialine 120).

Step 107

At step 107, the higher silanes generated in step 105 (line 120) arecombusted with the Si generated in step 101 (line 112) to yield at leastone silicon product. In the exemplified process, the combustion iscarried out in the presence of air (line 122), and the silicon productincludes SiO₂ and Si₃N₄. For higher silanes of the formula Si₃H₈, thereaction at step 108 may occur according to the following formula:

Si+Si₃H₈+3O₂+2N₂→SiO₂+Si₃N₄+4H₂O   (12)

Reactions similar to reaction (12) may occur for other higher silanes.

Additionally, some lower silanes may be combusted with the Si, accordingto the following formula:

3Si+SiH₄+2O₂+2N₂→SiO₂+Si₃N₄+2H₂O   (13)

Both reactions (12) and (13) are exothermic. Reaction (12) may yieldapproximately 4824 kJ/mol Si₃H₈. Reaction (13) may yield approximately4196 kJ/mol SiH₄.

In one particular example, step 107 may be carried out in a combustionchamber. The combustion chamber is preferably heated to above 1300° C.,and is preferably at a pressure of about 80 atm. Hot air may beintroduced to the combustion chamber at a temperature of between 2500°C. and 3000° C. Preferably, in order to avoid the formation of nitrogenoxides, the Si is added to the combustion chamber before the air, andafter the temperature is raised above 1300° C. The oxygen and nitrogenin the hot air may then spontaneously react with the silanes andsilicon. Syntheses of Si₃N₄ occurs above 1300° C. The generatedcombustion gases and dusts may be fed to an afterburner chamber, intowhich compressed cold air is introduced. The introduced cold air maycause a combustion of excess H₂ to form water vapor.

Both the resulting Si₃N₄ and the SiO₂ may be solid. The resultingmixture of Si₃N₄ and SiO₂ may be separated according to known methods,for example centrifugation.

Optionally, the SiO₂ generated at step 107 is recycled back to step 101(via line 124). The Si₃N₄ is optionally forwarded to step 109 (line126). The resulting water (line 128) may optionally be forwarded toother steps in the process requiring water, discarded, or used for otherpurposes.

Step 109

At steps 109, 113, 115, and 121, at least a portion of the magnesiumproducts formed in step 103 are further processed to yield Mg, and theMg is recycled back to step 101.

At step 109, the Mg(OH)₂ formed in step 103 (line 116) is reacted withthe Si₃N₄ formed in step 107 (line 126) to yield Mg₂SiO₄ and NH₃(ammonia). The reactions at step 109 may occur according to thefollowing formula:

Si₃N₄+6Mg(OH)₂→3Mg₂(SiO₄)+4 NH₃   (14)

Reaction (14) is exothermic, and may yield approximately 2586.7 kJ/molSi₃N₄.

In order to initiate the reaction the Si₃N₄ may be heated to atemperature of between about 1500° C. and 1800° C., and combined withthe 6Mg(OH)₂. The energy required to heat the Si₃N₄ may optionally beobtained from energy captured in steps 101, 103, or 105. Alternately,the energy required to heat the Si₃N₄ may be obtained from solar cellsfabricated from Si yielded in step 101.

The temperature of the resulting mixture may be cooled, for example to245° C. to yield NH₃ and crystals of Mg(OH)₂.

The NH₃ generated in step 109 is optionally forwarded to step 111 (vialine 128). The Mg₂(SiO₄) generated in step 109 is optionally forwardedto step 113 (via line 136).

Step 111

At step 111, the NH₃ is exothermically reacted with O₂ (line 130) toyield H₂O and N₂. The reactions at step 111 may occur according to thefollowing formula:

2NH₃+3O₂→6H₂O+N₂   (15)

Reaction (15) is exothermic, and may yield approximately 847.9 kJ/molNH₃.

The N₂ generated in step 111 is gaseous, and may optionally be releasedto the environment (line 132). The H₂O generated in step 111 (line 134)is vapor, and may optionally be forwarded to other steps in the processrequiring water, discarded, or used for another suitable purpose.

Step 113

At step 113 the Mg₂(SiO₄) produced in step 109 (line 136) is reactedwith HCl (line 138) to yield H₂O, MgCl₂, and SiO₂. The reactionsoccurring at step 114 may occur according to the following formula:

2Mg₂(SiO₄)+4HCl→SiO₂+2 MgCl₂+2 H₂O   (16)

Reaction (16) is endothermic, and may require approximately 976.0 kJ/molMg₂(SiO₄).

Preferably, the HCl is at a concentration of between 5 wt % and 10 wt %,and is heated to between 30° C. and 60° C. In alternate examples,another acid may be used.

The SiO₂ generated in step 113 is optionally recycled back to step 101(line 140). The H₂O generated in step 111 (line 140) may optionally beforwarded to other steps in the process requiring water, discarded, orused for another suitable purpose. The MgCl₂ generated in step 113 isforwarded to step 115 (line 144). Optionally, some of the MgCl₂ may beremoved form the cycle, and may optionally be used for other purposesoutside of process 100.

Step 115

At step 115, the MgCl₂ formed in step 113 (line 144) as well as theMgCl₂ formed in step 103 (line 118) is reacted with H₂O (line 146) toyield MgO, and HCl. The reactions occurring at step 115 may occuraccording to the following formulas:

MgCl₂+4H₂O→MgCl₂.4H₂O   (17)

MgCl₂.4H₂O→MgCl₂.2H₂O+2H₂O   (18)

MgCl₂.2H₂O→MgCl₂.H₂O+H₂O   (19)

MgCl₂.H₂O→MgO+2HCl   (20)

Reactions (17) to (20) are endothermic. Reaction (17) may requireapproximately 110.2 kJ/mol MgCl₂, reaction (18) may require about 71.0kJ/mol MgCl₂.4H₂O, reaction (19) may require approximately 44.8 kJ/molMgCl₂.2H₂O, and reaction (20) may require approximately 225.6 kJ/molMgCl₂.H₂O. Reaction (17) may be initiated by mixing the MgCl₂ and H₂O atroom temperature. Reactions (18) and (19) may be initiated by heatingthe mixture to about 180° C. At about 90° C., reaction (18) may begin tooccur. At about 120° C., reaction (19) may begin to occur. Preferably,the mixture is maintained below 200° C. while reactions (17) to (19) areoccurring, in order to avoid the formation of Mg₂OCl₂. In order toinitiate reaction (20) the mixture may be heated to 505° C.

The HCl produced in step 115 may optionally be forwarded to step 103 tobe used as a reactant (via line 148). The MgO produced in step 115 isoptionally forwarded to step 121 (via line 150).

Step 117

As mentioned hereinabove, in some examples, step 101 may be carried outin the presence of N₂, and at least some of the Mg may react with the N₂to yield Mg₃N₂. The Mg₃N₂ may optionally be further processed to produceMg, which can be forwarded back to step 101. For example, the Mg₃N₂ isforwarded to step 117 (via line 152). At step 117, the Mg₃N₂ isexothermically reacted with H₂O (line 154) to yield Mg(OH)₂ and NH₃. Thereactions at step 117 may occur according to the following formulas:

Mg₃N₂+6H₂O→SiO₂+3Mg(OH)₂+2 NH₃   (21)

The Mg(OH)₂ yielded in reaction (21) may be solid, and the NH₃ may begaseous. Reaction (21) is exothermic, and may yield approximately 449.0kJ/mol Mg₃N₂.

The NH₃ yielded in step 117 is optionally forwarded to step 111 (vialine 156), and reacted with O₂ to yield H₂O and N₂ as describedhereinabove.

The Mg(OH)₂ yielded in step 117 is optionally forwarded to step 119 (vialine 160)

Step 119

At step 119, the Mg(OH)₂ yielded in step 117 is heated to yield MgO andH₂O. The reaction at step 119 may occur according to the followingformula:

Mg(OH)₂→MgO+H₂O   (22)

Reaction (22) is endothermic, and may be initiated by heating the toMg(OH)₂ to between about 330° C. to 450° C. Reaction (22) may requireapproximately 37.02 kJ/mol.

The H₂O generated at step 119 (line 162) may optionally be used in othersteps of the process requiring water, discarded, or used for anotherpurpose.

The MgO generated at step 119 is optionally forwarded to step 121 (line164).

Step 121

At step 121 the MgO yielded in step 119 (line 164), as well a the MgOyielded in step 115 (line 150), is reacted with H₂ (line 166) to yieldH₂O, and Mg. The reactions at step 119 may occur according to thefollowing formula:

MgO+H₂→Mg+H₂O   (23)

Reaction (23) is endothermic, and may require approximately 315.67kJ/mol of energy. Reaction (23) may be initiated subjecting thereactants to a pressure of 2600 kBar. Over the course of the reaction,the reaction mixture may heat up, for example to a temperature ofbetween 2000° C. to 2500° C.

The products may subsequently be cooled to about 200° C. Preferably theproducts are cooled in the presence of SiO₂, for example in the presenceof SiO₂ recycled yielded in step 107, such that the Mg precipitates ontothe SiO₂, to form particles comprising Mg on a layer of SiO₂ granules,as described with respect to step 101.

The Mg yielded in step 121 is optionally recycled back to step 101 (vialine 168). The H₂O generated at step 121 (line 170) may optionally beused in other steps of the process requiring water, discarded, or usedfor another purpose.

Step 123

As mentioned hereinabove, at step 101, some MgO is generated. The MgOyielded in step 101 is optionally forwarded to step 123 (line 110),where it is processed to generate Mg which is recycled back to step 101.In the exemplified process, the MgO is reacted with CaO (line 170), andFeSi (line 172), in a process similar to the Pidgeon process, as isknown in the art. The reactions at step 123 may occur according to thefollowing formulas:

FeSi+2MgO+2 CaO→2Mg+Ca₂SiO₄+Fe   (24)

Reaction (24) is endothermic, and may require approximately 221.1 kJ/molFeSi. The reaction may be carried out in a retort, as is known in theart. The magnesium produced in step 123 is gaseous, and is preferablycooled and solidified, and recycled back to step 101 (line 174). TheCa₂SiO₄ (line 176) is optionally discarded, or used in any suitablemanner.

An alternate example of a process 200 in accordance with the presentinvention is shown in FIG. 2. Process 200 is similar to process 100, andin FIG. 2, like numerals are used to refer to like elements in FIG. 1,with the first digit incremented to 2 to refer to the Figure number.

Step 225

Process 200 differs from process 100 in that step 225 replaces step 123.At step 225 the MgO yielded in step 201 (line 210) is processed togenerate Mg, at least some of which is recycled back to step 201. In theexemplified process, step 225 comprises reacting the MgO with H₂ (line282) to yield Mg and H₂O. At least some of the Mg is recycled back tostep 201 (via line 274). The H₂O (line 284) may optionally be discarded,forwarded to other steps in the process, or used in another suitablemanner. Step 225 may be carried out as described hereinabove withrespect to step 121.

An alternate example of a process 300 in accordance with the presentinvention is shown in FIG. 3. Process 300 is similar to process 100, andin FIG. 3, like numerals are used to refer to like steps in FIG. 1, withthe first digit incremented to 3 to refer to the Figure number.

Step 327

Process 300 differs from process 100 in that step 115 is omitted.Instead, the MgCl₂ yielded in step 313 (line 344) and the MgCl₂ yieldedin step 303 (line 318) is forwarded to step 327. At step 327, the MgCl₂is reacted with NaOH (line 379) to yield Mg(OH)₂ and NaCl. The reactionsat step 327 may occur according to the following formulas:

MgCl₂+2NaOH→2NaCl+Mg(OH)₂   (25)

Reaction (25) is exothermic, and may yield approximately 250.8 kJ/molMgCl₂.

The NaCl yielded in step 327 is optionally forwarded to step 329 (line386). The Mg yielded in step 327 is optionally forwarded to step 331(line 388).

Step 329

At step 329, the NaCl yielded in step 329 is processed to yield HCl, asis known in the art. The HCl may optionally be forwarded to step 303(line 390) to be used as a reactant.

Step 331

At step 331, the Mg(OH)₂ generated in step 329 is heated to yield H₂Oand MgO. Step 331 may be carried out as described hereinabove withrespect to step 119.

The H₂O yielded in step 331 (line 392) may optionally be forwarded toanother step in the process requiring water, discarded, or used inanother suitable manner.

The MgO yielded in step 331 is forwarded to step 333 (via line 394).

Step 333

At step 333, the MgO yielded in step 331 (line 394) is reacted with H₂(line 377) to yield H₂O and Mg. Step 333 may be carried out as describedhereinabove with respect to step 121.

The Mg generated at step 333 may be recycled back to step 301 (line396). The H₂O (line 375) may optionally be forwarded to another step inthe process requiring water, discarded, or used in another suitablemanner.

An alternate example of a process 400 in accordance with the presentinvention is shown in FIG. 4. Process 400 is similar to process 100, andin FIG. 4 like numerals are used to refer to like steps in FIG. 1, withthe first digit incremented to 4 to refer to the Figure number.

Step 435

Process 400 differs from process 100 in that step 435 replaces step 103.At step 435, the Mg₂Si generated in step 401 (line 408) is reacted withH₂ (line 498) to yield lower silanes. The reactions at step 435 mayoccur according to the following formulas:

Mg₂Si+2H₂→2Mg+SiH₄   (26)

Reaction (26) is endothermic, and may require approximately 684 kJ/molSiH₄. In order to initiate reaction (26), the reactants may be mixed andheated to approximately 651° C.

Preferably, at least a portion of the Mg yielded in step 435 is recycledback to step 401 (line 499). The lower silanes are forwarded to step405, as described with respect to step 105.

Step 437

Optionally, as shown, the H₂ provided to step 435 may be formed at step437 by the electrolysis of water (line 497), as is known in the art, toyield H₂ (line 498) and O₂ (line 495). The energy required for this stepmay optionally be taken from any of the exothermic steps in the process,or may be generated by solar cells fabricated from Si yielded in step101.

Step 439

Process 400 additionally differs from process 100 in that step 439replaces step 123. At step 439, the MgO yielded in step 401 (line 410)is reacted with H₂O (line 473) to yield Mg(OH)₂. The reactions at step439 may occur according to the following formula:

MgO+H₂O→Mg(OH)₂   (27)

Reaction (27) is exothermic, and may yield approximately 608.68 kJ/mol.

The Mg(OH)₂ formed in step 439 is forwarded to step 409 (line 493), andis reacted with Si₃N₄ as described with respect to step 109.

Step 441

Process 400 additionally differs from process 100 in that step 441replaces step 113. At step 441, the Mg₂SiO₄ yielded in step 409 (line436) is heated to yield MgO, and SiO₂. The reactions at step 441 occuraccording to the following formula:

Mg₂SiO₄→2MgO+SiO₂   (28)

Reaction (28) is endothermic and may require 63.2 kJ/mol Mg₂SiO₄. Thereaction may be initiated by heating the starting product to 827° C. to927° C.

The SiO₂ generated in step 441 may be recycled back to step 401 (line491). The MgO may be forwarded to step 443 (line 489).

Step 443

At step 443, the MgO generated in step 441 is reacted with H₂ (line 483)to yield Mg and H₂O, as is described with respect to step 121.

The Mg generated at step 443 is recycled back to step 401 (line 487).The H₂O is optionally forwarded to step 445 (line 485).

Step 445

At step 445, the H₂ required for step 443 (line 483), and the O₂required for step 411 (line 430) is cyclically generated. That is, theH₂O generated in step 443 (line 485)and the H₂O generated in step 411(line 434) are forwarded to step 445. At step 445, the H₂O undergoes anelectrolysis process, as is known in the art, to yield H₂ and O₂. The H₂is forwarded back to step 443 (line 483), and the O₂ is forwarded backto step 411 (via line 430).

As mentioned hereinabove, in any of the above examples, a portion of thelower silanes, for example 10% to 30% of the lower silanes, may beremoved from the process (via line 180) and may be combusted in order togenerate energy. In an alternate example, all of the lower silanes maybe combusted in order to generate energy. That is, the process maycomprise step 101, 103, and a step of combusting the lower silanesgenerated in step 103.

It will be appreciated that in alternate examples, the furtherprocessing and recycling steps may be omitted.

It will be appreciated that in alternate examples, the products of thesteps described hereinabove may be processed in another manner. Forexample, at any time in the process, a portion of the products may beremoved from the process. For example, some of the MgCl₂ generated instep 103 may be removed and sold.

It will be appreciated that the energy generated in any of theexothermic steps of the process may be used to power any of theendothermic steps of the process or to initiate any of the exothermicsteps of the process. Alternately, energy may be obtained from a sourceoutside the process to power any of the endothermic steps of the processor to initiate any of the exothermic steps of the process. Alternately,any of the silicon generated in the process may be used to make solarcells, and solar energy generated by the solar cells may be used topower any of the endothermic steps of the process or to initiate any ofthe exothermic steps of the process.

It is envisioned that in alternate examples, rather than Mg, anotheralkaline earth metal, such as Mg, Ca, Be, Sr, Ba, or Ra may be used

1. A process for generating energy comprising: a) exothermicallyreacting Mg with SiO₂ to yield at least Mg₂Si and Si; b) reacting theMg₂Si to yield at least lower silanes, and at least one magnesiumproduct; c) generating at least higher silanes from at least a portionof the lower silanes; and d) combusting the higher silanes and the Si toyield at least one silicon product.
 2. The process of claim 1, furthercomprising: e) processing at least a portion of the magnesium product toyield Mg, and recycling at least a portion of the Mg back to step (a).3. The process of claim 1, wherein the silicon product comprises SiO₂,and the process further comprises recycling at least a portion of theSiO₂ back to step (a).
 4. The process of claim 2, further comprisinginputting at least a portion of the energy generated in steps (a) and(d) in to the further processing of step (e).
 5. The process of claim 1,wherein the lower silanes comprise at least SiH₄ and Si₂H₆.
 6. Theprocess of claim 5, wherein the higher silanes are of the formulaSi_(n)H_(2n+2), wherein n is at least
 3. 7. The process of claim 6,wherein step (c) comprises decomposing the SiH₄ to yield SiH₂, andreacting the SiH₂ with the Si₂H₆ to yield the higher silanes.
 8. Theprocess of claim 2, wherein: i) step (b) comprises reacting the Mg₂Siwith HCl to yield the lower silanes, H₂, and the magnesium product,wherein the magnesium product comprises a first amount of MgCl₂, and afirst amount of Mg(OH)₂ ii) the at least one silicon product comprisesSi₃N₄; iii) the further processing of the magnesium product of step (e)comprises exothermically reacting the first amount of Mg(OH)₂ with theSi₃N₄ to yield Mg₂SiO₄, and a first amount of NH₃.
 9. The process ofclaim 8, wherein: i) step (a) is carried out in the presence of N₂, andat least a portion of the Mg reacts with the N₂ to yield Mg₃N₂; and ii)the process further comprises exothermically reacting the Mg₃N₂ with H₂Oto yield a second amount of NH₃, and a second amount of Mg(OH)₂.
 10. Theprocess of claim 9, further comprising exothermically reacting the firstamount of NH₃ and the second amount of NH₃ with O₂ to yield H₂O, and N₂.11. The process of claim 9, further comprising: heating the secondamount of Mg(OH)₂ to yield MgO; reacting the MgO with H₂ to yield H₂Oand Mg; and recycling the Mg back to step (a).
 12. The process of claim8, wherein the further processing of the magnesium product of step (e)further comprises: treating the Mg₂SiO₄ with HCl to yield H₂O, a secondamount of MgCl₂ and SiO₂; reacting the first amount of MgCl₂ and thesecond amount of MgCl₂ with H₂O to yield at least MgO; and reacting theMgO with H₂ to yield at least some of the Mg.
 13. The process of claim12, further comprising recycling the SiO₂ back to step (a).
 14. Theprocess of claim 8, wherein the further processing of the magnesiumproduct of step (e) comprises: reacting the Mg₂SiO₄ with HCl to yieldH₂O, a second amount of MgCl₂ and SiO₂; exothermically reacting thefirst amount of MgCl₂ and the second amount of MgCl₂ with NaOH to yieldMg(OH)₂, and NaCl; heating the Mg(OH)₂ to yield MgO; and reacting theMgO with H₂ to yield H₂O and at least some of the Mg.
 15. The process ofclaim 14, further comprising processing the NaCl to yield at least someof the HCl used in step (b).
 16. The process of claim 1, wherein thereaction of Mg and SiO₂ further yields MgO, and the process furthercomprises processing the MgO to yield at least some of the Mg used instep (a).
 17. The process of claim 16, wherein processing the MgOcomprises reacting the MgO with H₂ to yield H₂O and at least at least aportion of the Mg used in step (a).
 18. The process of claim 2, whereinstep (e) comprises recycling greater than 90% of a total Mg amount backto step (a).
 19. A process for generating energy comprising: a)exothermically reacting Mg with SiO₂ to yield at least Mg₂Si and Si; b)reacting the Mg₂Si with H₂ to yield at least lower silanes, and Mg; c)generating at least higher silanes from the lower silanes; and d)combusting the higher silanes and the Si to yield at least one siliconproduct.
 20. The process of claim 19, further comprising: e) recyclingat least a portion the Mg yielded in step (b) back to step (a);
 21. Theprocess of claim 19, wherein the silicon product comprises SiO₂, and theprocess further comprises recycling at least a portion of the SiO₂yielded in step (d) back to step (a).
 22. A process for generatingenergy comprising: a) exothermically reacting Mg with SiO₂ to yield atleast Mg₂Si and Si; b) reacting the Mg₂Si to yield at least lowersilanes, and at least one magnesium product; and c) combusting at leasta portion of the lower silanes.